Scaffolding matrix with internal nanoparticles

Abstract

A battery electrode composition is provided comprising composite particles, with each composite particle comprising active material and a scaffolding matrix. The active material is provided to store and release ions during battery operation. For certain active materials of interest, the storing and releasing of the ions causes a substantial change in volume of the active material. The scaffolding matrix is provided as a porous, electrically-conductive scaffolding matrix within which the active material is disposed. In this way, the scaffolding matrix structurally supports the active material, electrically interconnects the active material, and accommodates the changes in volume of the active material.

The invention claimed is: 
     
       1. A battery electrode composition, comprising:
 a composite particle, comprising:
 active material that is electrochemically reactive with metal ions during battery operation; and 
 a porous scaffolding matrix comprising a monolithic particle within which the active material is at least partially disposed, 
 wherein the porous scaffolding matrix electrically interconnects the active material. 
 
 
     
     
       2. The battery electrode composition of  claim 1 , further comprising:
 a coating to inhibit contact of solvent molecules of an electrolyte with the active material. 
 
     
     
       3. The battery electrode composition of  claim 1 , further comprising:
 a coating permeable to the metal ions. 
 
     
     
       4. The battery electrode composition of  claim 1 , further comprising:
 a coating to inhibit contact of solvent molecules of an electrolyte with the active material, and that is permeable to the metal ions. 
 
     
     
       5. The battery electrode composition of  claim 1 , wherein the active material comprises Si, In, Sn, Sb, or Ge. 
     
     
       6. The battery electrode composition of  claim 1 , wherein the monolithic particle comprises carbon. 
     
     
       7. The battery electrode composition of  claim 1 , wherein the metal ions comprise one or more of: Li + , Na + , Mg 2+ , or Ca 2+ . 
     
     
       8. A cylindrical, prismatic, or pouch battery, comprising:
 an anode and a cathode, 
 wherein at least one of the anode and the cathode comprises the battery electrode composition of  claim 1 . 
 
     
     
       9. The battery electrode composition of  claim 1 , wherein the porous scaffolding matrix comprises one or more micropores with a first pore size below 2 nm and one or more mesopores with a second pore size between 2 nm and 50 nm. 
     
     
       10. The battery electrode composition of  claim 9 , wherein the active material comprises Si, In, Sn, Sb, or Ge. 
     
     
       11. The battery electrode composition of  claim 9 , wherein the metal ions comprise one or more of: Li + , Na + , Mg 2+ , or Ca 2+ . 
     
     
       12. A cylindrical, prismatic, or pouch battery, comprising:
 an anode and a cathode, 
 wherein at least one of the anode and the cathode comprises the battery electrode composition of  claim 9 . 
 
     
     
       13. The battery electrode composition of  claim 1 , wherein a pore size of one or more pores in the porous scaffolding matrix is in a range from 0.5 nm to 5 nm. 
     
     
       14. The battery electrode composition of  claim 13 , wherein the active material comprises Si, In, Sn, Sb, or Ge. 
     
     
       15. The battery electrode composition of  claim 13 , wherein the metal ions comprise one or more of: Li + , Na + , Mg 2+ , or Ca 2+ . 
     
     
       16. A cylindrical, prismatic, or pouch battery, comprising:
 an anode and a cathode, 
 wherein at least one of the anode and the cathode comprises the battery electrode composition of  claim 13 . 
 
     
     
       17. A method of fabricating a battery electrode composition comprising a composite particle, the method comprising:
 forming a porous scaffolding matrix by:
 processing a precursor particle; 
 carbonizing the processed precursor particle to form a carbonized particle; and 
 activating the carbonized particle by physical activation at an elevated temperature with an oxygen-comprising gas; and 
 
 introducing active material into the porous scaffolding matrix, wherein the active material is electrochemically reactive with metal ions during battery operation. 
 
     
     
       18. The method of  claim 17 , wherein the processing of the precursor particle comprises oxidizing the precursor particle. 
     
     
       19. The method of  claim 17 , further comprising:
 covering the composite particle with a polymer layer. 
 
     
     
       20. The method of  claim 19 , wherein the polymer layer is carbon forming. 
     
     
       21. The method of  claim 17 , wherein the active material comprises Si, In, Sn, Sb, or Ge. 
     
     
       22. The method of  claim 17 , wherein the metal ions comprise one or more of: Li + , Na + , Mg 2+ , or Ca 2+ . 
     
     
       23. A method of fabricating a battery electrode composition comprising at least one composite particle, the method comprising:
 forming a porous scaffolding matrix by:
 carbonizing a polymer monolith to form a carbon monolith; 
 forming at least one monolithic particle from the carbon monolith; and 
 activating the at least one monolithic particle; and 
 
 introducing active material into the at least one monolithic particle. 
 
     
     
       24. The method of  claim 23 , wherein the active material comprises Si, In, Sn, Sb, or Ge. 
     
     
       25. A method of fabricating a battery electrode composition comprising a composite particle, the method comprising:
 forming a porous scaffolding matrix comprising a monolithic particle within which active material is at least partially disposed, 
 wherein the active material is electrochemically reactive with metal ions during battery operation, and 
 wherein the porous scaffolding matrix electrically interconnects the active material. 
 
     
     
       26. The method of  claim 25 , wherein the porous scaffolding matrix comprises one or more micropores with a first pore size below 2 nm and one or more mesopores with a second pore size between 2 nm and 50 nm. 
     
     
       27. The method of  claim 25 , wherein the active material comprises Si, In, Sn, Sb, or Ge. 
     
     
       28. The method of  claim 25 , wherein the metal ions comprise one or more of: Li + , Na + , Mg 2+ , or Ca 2+ . 
     
     
       29. A method of fabricating a battery electrode composition comprising composite particles, the method comprising:
 forming a porous scaffolding matrix by:
 pyrolyzing a precursor particle to form a pyrolyzed particle; and; 
 activating the pyrolyzed particle by physical activation at an elevated temperature with an oxygen-comprising gas; and 
 
 introducing active material into the matrix, wherein the active material is electrochemically reactive with metal ions during battery operation. 
 
     
     
       30. The method of  claim 29 , wherein the active material comprises Si, In, Sn, Sb, or Ge. 
     
     
       31. The method of  claim 29 , wherein the metal ions comprise one or more of: Li + , Na + , Mg 2+ , or Ca 2+ .